Chengdu Aigre technology Co.

, Ltd

Training for
Seamless rail line
welding construction
UN5-150ZB1 On-site mobile welding
 Chengdu Aigre seamless rail line welding
construction training
（On-site mobile welding）

成都艾格无缝线路焊接施工培训教材
（现场移动焊）

Forward

前言

For the construction of new railways, the on-site welding of steel rails needs to
be carried out. The 500m long rails are flash-welded by a mobile flash butt welder to
form a complete seamless line. Provide a more stable and safe loading platform for
high-speed trains.

新建铁路在无缝线路铺设中需要进行钢轨现场焊接施工，将

500m 的长轨通过移动式闪光对焊机进行闪光焊接连成整条无缝线路，

以确保整条线路的连续和稳定，提供给高速列车更平稳和安全的承载

平台。

Seamless line flash welding construction is a construction method using 500mm

long rails for unit welding and lock welding using a mobile flash rail welding machine.
Detailed construction plans and technical details of each construction process need to
be formulated. Online welding construction In the process, construction is strictly
carried out in accordance with the construction specifications and construction
technology to ensure the quality of seamless line welding construction and the safety
of construction personnel.

无缝线路闪光焊接施工是利用移动式闪光焊轨机将 500m 长轨进

行单元焊和锁定焊的一种施工方法，需要制定详细的施工方案和各施
1
工流程的技术交底资料，在上线焊接施工过程中严格按照施工规范和

施工技术交底进行施工，确保无缝线路焊接施工的质量和施工人员的

安全。
This training textbook uses the UN5-150ZB1 mobile flash welding machine
manufactured by Chengdu Iger as the main construction equipment. It focuses on the
construction process and technical specifications during the construction and
production process, in order to guide the welding rail construction operators to protect
the construction personnel's Under the premise of personal safety, perform
high-quality and efficient welding rail construction operations to ensure the seamless
completion of the new line construction.

本培训教材以成都艾格生产的 UN5-150ZB1 型移动式闪光焊轨机

为主要施工设备，着重于讲述施工生产过程中的施工流程和技术规范，

以指导从事焊轨施工操作人员在保障施工人员的人身安全的前提下

进行优质高效的焊轨施工作业，确保新线建设无缝线路铺设顺利完成。

Welding rail construction process and technical specifications

焊轨施工流程及技术规范

I. Technical Coverage: Suitable for welding rail joints at the junction of seamless
rails
一、技术涵盖范围：适用于无缝线路长轨相连处钢轨接头焊接
II. The process:
二、工艺流程：
Basic process: Pre-welding inspection of rails → Straightening of rails →
Descaling before welding → Welding and protruding → Rough grinding → Post-weld
heat treatment → Straightening of welded joints → Shape finishing and flatness
inspection → Ultrasonic flaw detection
基本工序： 钢轨焊前检查 → 矫直钢轨 → 焊前除锈 → 焊接和推凸 →
粗磨 → 焊后热处理 → 焊接接头矫直 →外形精整及平直度检验 → 超声波探
伤

2
 III. The construction steps
三、施工作业步骤
3.1 Construction Preparation --- Inspection and Descaling of Rails
3.1 施工准备 ---钢轨焊前检查与除锈
3.1.1 Operating standards
3.1.1 作业标准
1) Check the rail model, brand, place of origin, and smelting number.
1)检查钢轨型号、牌号、产地、熔炼号。
2) Welding rails shall be inspected before welding in accordance with the
technical conditions of rail ordering. Unqualified rails shall be sawed off and welding
shall not be allowed.
2)应依照钢轨订货技术条件对待焊钢轨进行焊前检查，不合格的钢轨要求锯
掉，不许焊接。
3) Check the surface quality of the rails one by one: Inspect the appearance of
the rails for hard bends, twists, cracks, folds, scratches, indentations, bumps and other
defects. If you find any failure, you must saw off.
3)逐根检查钢轨表面质量: 检验钢轨外观有无硬弯、扭曲、裂纹、折叠、划
痕、压痕、碰伤等缺陷，如发现不合格必须锯掉。
4) Measuring tools and templates should be used, and the rail type dimensions
should be checked one by one: rail height, rail head width, rail bottom width,
asymmetry of section, end face inclination, end bending, end face inclination, which
should meet the requirements of the following table. The cracks of the rails to be
welded and hard bends, twists, heavy skins, ash inclusions, scars, scratches, etc. that
need to be welded need to be replaced. The inspection results of all rails should be
recorded on the rail inspection record sheet.
4)应使用量具及样板，逐根检查钢轨型式尺寸：钢轨高度，轨头宽度，轨底
宽度，断面不对称，端面斜度，端部弯曲，端面斜度，应符合下表要求，如发现
待焊钢轨裂纹和超标的硬弯、扭曲、重皮、夹灰、结疤、划痕损伤等，需作更换
处理，所有钢轨的检查结果应在钢轨检查记录表上做好记录。
表 4： 钢轨母材外观尺寸要求
尺寸及允许偏差 单位（毫米）
Table 4: Dimensional requirements of rail base metal
Size and tolerance Unit (mm)
160km/ 250km/
200km/h 300km/h 350km/h
h h
Rail
±0.6 ±0.6 ±0.6 ±0.6 ±0.6
height
Rail head
±0.5 ±0.5 ±0.5 ±0.5 ±0.5
height
Rail +1 -0.5 +1 -0.5 +1 -0.5 +1 -0.5 +1 -0.5

3
waist
thickness
Rail +1
±1 ±1 ±1 ±1
bottom width -1.5
Rail bottom
Rail bottom
Bottom thickness
+0.75 +0.75 thickness 20mm +0.75
of rail Edge 20mm from rail
-0.5 -0.5 from rail bottom -0.5
thickness bottom edge ±
edge ± 0.5
0.5
Bottom
≤0.4 ≤0.3 ≤0.3 ≤0.3 ≤0.3
rail depression
Face
≤0.8 ≤0.6 ≤0.6 ≤0.6 ≤0.6
slope
Asymmet
±1.2 ±1.2 ±1.2 ±1.2 ±1.2
ry
160km/ 250km/
200km/h 300km/h 350km/h
h h
钢 轨 高
±0.6 ±0.6 ±0.6 ±0.6 ±0.6
度
轨 头 高
±0.5 ±0.5 ±0.5 ±0.5 ±0.5
度
轨 腰 厚
+1 -0.5 +1 -0.5 +1 -0.5 +1 -0.5 +1 -0.5
度
轨 底 宽 +1
±1 ±1 ±1 ±1
度 -1.5
离轨底边 离轨底边
轨底边 +0.75 +0.75 +0.75
缘 20mm 的 轨 缘 20mm 的轨底
缘厚度 -0.5 -0.5 -0.5
底厚度±0.5 厚度±0.5
轨 底 凹
≤0.4 ≤0.3 ≤0.3 ≤0.3 ≤0.3
陷
端 面 斜
≤0.8 ≤0.6 ≤0.6 ≤0.6 ≤0.6
度
端 面 不
±1.2 ±1.2 ±1.2 ±1.2 ±1.2
对称

3.1.2 Work tools and work methods

3.1.2 作业工具及作业方法
1) Working tools: rail saw, end grinder1)作业工具：锯轨机 、端磨机
2) Operation method:
2)作业方法：
Rail sawing machine 锯轨机
When cutting a rail with a rail saw, the operator stands on the side of the rail,
holds the handle with his left hand, presses the throttle with his index finger, and starts
4
cutting at half speed from the top of the rail with the engine. Once the slot is cut,
continue to cut at full speed . To cut straight and keep the grinding wheel vertical,
when the grinding wheel is cut into the rail, the engine needs to run at full speed. At
this time, the grinding wheel should be fully swung to obtain the most effective
cutting. When cutting more than half of the time, the front end of the machine housing
must be probed into the gap at the waist of the rail, and the grinding wheel can be
swung up and down in a small area until the bottom of the rail is completely cut.
When the grinding wheel has a certain degree of wear and cannot cut the rail at one
time, the grinding wheel cover can be adjusted and the reverse function of the guide
frame can be used to continue cutting.
用锯轨机切割钢轨时操作者站在锯轨机一侧，左手握住手把，食指按住油门，
自轨顶向下用发动机半速开始切割，一旦切割出槽口，再全速继续切割。要直线
切割并使砂轮片保持垂直，当砂轮片切入钢轨时，发动机需全速运转，此时要充
分摆动砂轮片，以获得最有效的切割。当切割过半时，须将连机壳体前端探入钢
轨腰部空隙，小范围上下摆动砂轮片，直至将钢轨底部完全切割。当砂轮片有了
一定磨损不能一次切下钢轨时，可调整砂轮护罩，利用导向架的反向功能继续切
割。
End grinder 端磨机
Use the positioning fixture to fix the end grinder on the steel rail to be polished,
turn the nut to keep the grinding wheel at a certain distance from the end surface of
the rail, start the end grinder, adjust the feed nut, and the feed should not be too large
during grinding, so that the rail does not appear Blackening and bluishness result in
burns. If grinding burns occur, reduce the feed and continue grinding until the test
with a square ruler passes.
用定位夹具将端磨机固定在所要打磨的钢轨上，转动螺母，使砂轮与钢轨端
面保持一定距离，启动端磨机，调整进给螺母，打磨时进给量不能太大，不能使
钢轨出现发黑、发蓝的现象形成打磨灼伤。如果出现打磨灼伤，应减小进给量继
续打磨，直到用直角尺检测合格为止。
Note: If it is raining or snowing after the sanding, protective measures must
be taken to prevent the sanding area from rusting.
注意：打磨后如遇雨雪天气必须采取防护措施，防止打磨区域生锈 。
3.1.3 Testing gages and methods used
3.1.3 所用检测量具及检验方法
1) Detection tools
1)检测工具
1.60Kg / m steel rail model
2.2m steel flat rail
3.Rail distortion measuring ruler
4.square ruler
1.60Kg/m 钢轨轨型样板
5
 2.2m 钢轨平尺
3.钢轨扭曲度测量尺
4.直角尺
2) Inspection method
2)检验方法
1. Visual inspection: check the appearance of the rails for hard bends, cracks,
folds, scratches, indentations, bumps and other defects.
1.目测观察：检查钢轨外观有无硬弯、裂纹、折叠、划痕、压痕、碰伤等缺
陷。
2. Rail twist measuring ruler: used for rail twist detection (see Appendix 1 for
usage).
2.钢轨扭曲度测量尺：用于钢轨扭曲度检测（使用方法见附件 1） 。
3.60Kg / m rail rail type sample detection rail end.
3.60Kg/m 钢轨轨型样板检测钢轨端头。
4. 2m rail flat ruler: used for flatness detection. The rail temperature should be
lower than 50 ℃ and the measurement length should be 2 meters. Place the flat ruler
on the longitudinal centerline of the top surface of the rail and press one end of the
ruler. If there is a gap between the other end of the ruler and the top surface of the rail,
the flatness of the rail end is downward. Use a feeler gauge to check the gap. Not
more than 0.2mm is qualified. If there is a gap between the middle of the ruler and the
top surface of the rail, it means that the straightness of the end of the rail is upward.
Use a feeler to measure the distance. The flat ruler is placed on the longitudinal line of
the rail end 16 mm from the top surface of the rail, and the gap between the flat ruler
and the rail is detected with a feeler gauge.
4. 2m 钢轨平尺：用于平直度检测。进行平直度检测时钢轨温度应低于 50℃，
测量长度为 2 米。将平尺放在轨端钢轨顶面纵向中心线上，按住尺子一端，如果
尺子另一端与钢轨顶面之间有间隙，说明轨端的平直度是向下，用塞尺检测间隙
大小，不大于 0.2mm 为合格。如果尺子的中间与钢轨顶面之间有间隙，说明轨端
的平直度是向上，用塞尺检测距离，不大于 0.4mm 为合格。将平尺放在轨端的工
作面上距轨顶面 16mm 处的纵向线上，用塞尺检测平尺与钢轨之间的间隙，不大
于 0.6mm 为合格。
5.Rectangular ruler: used to measure the slope of the end face of the rail. The end
face slope is acceptable if it is 0.6mm or less.
5.直角尺：用于测量钢轨端面斜度，端面斜度在 0.6mm 及其以下即为合格。
3.2 Disassembly of fasteners and pad rollers
3.2 拆卸扣件、垫滚筒
3.2.1 Operating standards
3.2.1 作业标准
1) After removing all the long rails in front of the rail joint to be welded and the
6
fasteners within a range of 10 meters behind, the length of the removed fasteners
meets the requirements of the welded rails. Check the rail end geometry and
straightness. The disassembled buckle fittings should be regularly placed on the inside
of the track board or stored in a tool box, and must not be lost.
1)拆除待焊钢轨接头前方全部长钢轨及后方 10 米范围内的扣件后方拆除扣
件长度满足焊轨要求，检查轨端几何尺寸及平直度。拆卸后的扣配件要有规律的
放在轨道板的内侧或用工具箱存放，不得遗失。
2) According to the type of sleepers and fasteners, properly raise the rails behind
the rail joint to be welded to ensure the straightness of the top surface of the joint.
2)根据轨枕和扣件类型适当垫高待焊钢轨接头后方的钢轨，以确保接头顶面
平直度。
3) A roller is placed every 12.5 meters under the long rail in front of the rail joint
to be welded to reduce the longitudinal movement resistance of the rail. When
welding on curved sections or long ramps, reduce the pad spacing and ensure smooth
longitudinal movement of the rails. 3)待焊钢轨接头前方长钢轨下每隔 12.5 米安放
一个滚筒，减少钢轨纵向移动阻力。在曲线段或长大坡道处焊接时，减少滚筒垫
放间距，保证钢轨纵向移动顺畅。
Note: The centerline of the drum must be on the same line as the centerline
of the rail bearing groove to ensure the synchronization of the drum.
注意：滚筒中心线必须与钢轨承轨槽中心线保持在同一直线上，以确保滚
筒的同步性。
3.3 Descaling before rail welding
3.3 钢轨焊前除锈
3.3.1 Operating standards 3.3.1 作业标准
1) Use a hand-held grinder to remove rust manually.
1)使用手持砂轮机人工除锈。
2) Derusting parts: The end faces of the rails to be welded, the contact points
between the rails and the electrodes of the flash welder, and the grinding length must
meet the requirements of the welder.
2)除锈部位：待焊钢轨端面、钢轨与闪光焊机电极接触部位,打磨长度要符
合焊机的要求。
3) The grinding amount of the base material does not exceed 0.2mm.
3)母材打磨量不超过 0.2mm。
4) After derusting, the surface should be welded for more than 24 hours or
decontaminated if there is contamination.
4)除锈后的表面待焊时间超过 24 小时、或有污染时应重新除锈
5) When the electrode clamps the rail waist, the hot rolled protrusion mark on the
surface of the rail should be polished at the same time

7
 5)电极夹持轨腰时，应同时打磨掉钢轨表面热轧突起标志
6) Longitudinal grinding in the direction of the rails is prohibited, and horizontal
grinding is prohibited
6)应沿钢轨方向纵向打磨，禁止横向打磨
3.3.2 Working tools and methods
3.3.2 作业工具及作业方法
1) Working tools: hand-held grinder, 5KW diesel generator, crowbar (2), jack (1)
1）作业工具：手持砂轮机、5KW 柴油发电机、撬棍（2 根） 、起道器（1 个）
2) Operation method
2）作业方法
Before welding, use a portable grinder to remove the rust on the rail waist. The
length of the rust removal should meet the requirements of the welding machine used.
The surface after rust removal should be prevented from being contaminated. The
marking shall be smooth and smooth. The quality requirements for the derusting and
grinding of the rail waist are as follows:
焊接前对钢轨接头轨腰部位要使用手提式砂轮机打磨除锈，除锈长度应符合
所用焊机的要求，除锈后的表面应防止被污染；焊机电极夹持钢轨部位的热轧凸
起标志应打磨平整。轨腰除锈打磨质量要求如下：
The rust-removed parts of the rails need to be polished to expose the true color of
the metal, and if there is a protruding rail production logo at the rail waist, it must be
polished flat. When grinding the rail waist to remove rust, the grinding shall be
carried out longitudinally along the direction of the rail. The grinding wheel cannot be
stopped at the same position to avoid the temperature at the grinding position being
too high, forming a quenched layer (that is, the temperature rises instantly and
decreases immediately). After rust removal and grinding, no obvious uneven surface
and scratches are allowed. The grinding amount of the base metal during grinding
shall not exceed 0.2mm. The steel rail to be welded has been left for more than 24
hours after rust removal and grinding, or the grinding part has rusted, and grinding
should be performed again.
钢轨除锈部位需要打磨至露出金属本色，轨腰处如有凸出的钢轨生产标识必
须打磨平整。轨腰打磨除锈时，要顺钢轨方向纵向打磨，打磨砂轮不能停在同一
部位打磨，避免打磨位置温度过高，形成淬火层（即温度瞬间升高，又马上降低）。
除锈打磨后不允许存在明显的凹凸面及划痕，打磨时对母材的磨削量不得超过
0.2mm。待焊钢轨除锈打磨后的放置时间超过 24 小时或者打磨部位已生锈，应重
新进行打磨。
Welding can only be carried out after grinding after checking the qualified rail
joints.
打磨后经检查合格的钢轨接头，才能进行焊接。
3.3.3 Safe operating procedures
3.3.3 安全操作规程
8
 1) Descaling operators must be trained and certified to work;
1）除锈作业人员必须经过培训，持证上岗；
2) Descaling operators should be familiar with the performance and operation
methods of the equipment;
2）除锈作业人员应熟悉设备的性能和操作方法；
3) Ensure that the equipment is in normal condition and maintain the equipment
in accordance with the requirements of the equipment manual;
3）保证设备状态正常，按照设备说明书要求保养设备；
4) When using a hand-held grinder for rust removal, a leakage protector must be
installed.
4）使用手持砂轮机进行除锈作业时，必须安装漏电保护器。
5) In the process of using the hoisting machine, it is necessary to avoid people
from being crushed and injured. When using the hoisting machine to pry up the rail
pad rollers, prevent the crowbar from flying out and hurt people.
5）使用起道机的过程中要避免人员挤伤碰伤，使用起道机撬起钢轨垫滚轮
时要防止撬棍飞出伤人。
6) It is strictly forbidden to smoke or place the gasoline generator near
high-temperature places, and pay attention to the safety of electricity when using the
gasoline generator.
6）严禁在汽油发电机附近吸烟或将其放在高温的地方，使用汽油发电机时
注意用电安全。
3.4 Rail welding machine alignment and welding
3.4 焊轨机对位、焊接
3.4.1 Operating standards
3.4.1 作业标准
1) Check the welding machine before welding, and confirm that the welding
machine is in a normal state, the voltage is normal, the oil level and oil temperature
are normal, and the welding machine has no alarm.
1）焊前检查焊机，应确认焊机状态正常，电压正常，油位、油温正常，焊
机无报警。
2) Before welding, check the equipment operation records, welding records, and
welding tasks, check the welding program number, and confirm that there are no
errors before welding. It is forbidden to modify welding parameters without
permission. If the modification is required, it shall be approved by the competent
engineer.
2）焊接前查看设备运转记录、焊接记录表、焊接任务交底，查验焊接程序
号，确认无误后方可焊接。禁止私自改动焊接参数，如需改动应经过主管工程师
批准。
3) Promote the initial positioning of the mobile rail welding machine at a speed
of 3-5 kilometers per hour. The first wheelset of the railcar carrying the mobile

9
welding machine is about 2.8m away from the welding position. After the alignment
is completed, the wheel stopper should be installed quickly. To ensure that the vehicle
will not slip. After the alignment, the hydraulic outriggers should be lowered and the
welding rail operation vehicle be raised. In the process of jointing, it should be noted
that the rail top surface and working surface must be used as the reference. The
deviation between the top surface and the working surface of the rail should not be
greater than 0.2mm, and the deviation at the bottom edge of the rail should not be
greater than 1mm. Considering the influence of temperature and the influence of train
passing after welding, an arch amount of 0.1-0.2 is set before welding.
3）以每小时 3-5 公里的速度推进移动焊轨机初定位，载有移动焊机的轨道
车第一个轮对距焊接位置 2.8m 左右，对位完成后应迅速装好止轮器，保证车辆
不会发生溜车现象。对位之后应放下液压支腿，顶升起焊轨作业车。在接头对接
过程中，应注意必须以轨顶面和工作面为基准，轨顶面和工作面错位偏差不应大
于 0.2mm，轨底边缘错位偏差不应大于 1mm。考虑到温度影响及焊接后列车通过
的影响，在焊接前设置 0.1—0.2 的上拱量。
4) The electrode surface of the welding machine should be flat, smooth and free
of pollutants such as oil, water and iron slag.
4）焊机电极表面应平整、光洁，无油、水、铁渣等污染物。
5) Welding slag should not be squeezed into the base metal; welding slag should
not scratch the base metal. When the temperature is below 0 degrees and bad weather,
it is not suitable to carry out welding operations on the construction site. Welds that
are subjected to tension should be kept under pressure when the rail temperature is
higher than 400 degrees. It should be less than 25m, and the material is the same as
the original steel rail. After welding, the technical status of the original seamless line
and the locked rail temperature should be maintained.
5）不应将焊渣挤入母材；焊渣不应划伤母材。气温在 0 度以下及恶劣天气
时，不宜进行工地焊接作业；承受拉力的焊缝，在其轨温高于 400 度时应持力保
压；锁定焊接需要插入短轨时，插入短轨长度不应小于 25m，材质与原钢轨相同，
焊后应保持原无缝线路技术状态和锁定轨温不变。
6) The phase deviation of the left and right strand rail joints cannot exceed
100mm.
6）左右股轨节接头相错量不能超过 100mm。
7) When the weld area is cooled below 400 ° C, the rail welding vehicle can pass
the rail welding head.
7）焊缝区域冷却到 400℃以下时，焊轨作业车方可通过钢轨焊头。
8) For each joint welded, the welding operator should clean the welder, check the
surface quality of the joint, the quality of the protrusion, the amount of misalignment
of the joint, the presence or absence of electrode burns, the welding record curve,
complete the joint identification, check the rail furnace number, and fill in the welding
production. Record Form.

10
 8）每焊接一个接头，焊接作业人员应清扫焊机、检查接头表面质量、推凸
质量，接头错边量、有无电极灼伤、焊接记录曲线，完成接头标识，查看钢轨炉
号，填写焊接生产记录表。
Note: If electrode burns occur, re-soldering must be removed.
注意：如果出现电极灼伤必须切掉重焊。
9) The joint identification shall correspond to the rail marks, welding records or
reports. The center of the font of the identification code should be on the neutral axis
of the rail, and it should be marked on the non-working side of the rail.
9）接头标识应与钢轨标记、焊接记录或报表对应。标识代码字体中心应在
钢轨中性轴上，宜标记在钢轨非工作面一侧，标识应在焊接接头前方 3～5m 处的
轨腰部位。
The numbering rules are as follows:
编号规则如下：
ZT2431 110407 11
The top four ZT24 are the 24th bureau of China Railway
The fifth position is 3 for mobile flash welding, and 4 is for aluminizing.
The 6th digit is the group code. For example, 1 is the first group.
Numbers 7-12 are dates
The last two digits are the sequence number
Leave one space before and after the date.
The character height is 50mm, the width factor is 0.6, and the font is bold.
前四位 ZT24 为中铁二十四局
第 5 位 3 为移动闪光焊，4 为铝热焊。
第 6 位为组别代号，如 1 为第 1 组，
第 7－12 位为日期
最后两位为顺序号
日期前、后留一位空格。
字高为 50mm，宽度系数为 0.6，字体为黑体。
10) There should be no cracks on the surface of the joint; there is no damage to
the rail base material during the push-out process. The push-out allowance: the rail
head should be no more than 1mm, the rail waist should be no more than 2mm, and
the rail bottom should be no more than 1mm.
10）接头表面应无裂纹；推凸过程中没有损伤钢轨母材，推凸余量：轨头应
不大于 1mm，轨腰应不大于 2mm，轨底应不大于 1mm。
11) Check the amount of misalignment of the joint without sanding. The top
surface of the joint is not greater than 0.2mm, the working edge of the side of the rail
head is not greater than 0.2mm, the horizontal edge of the rail foot is not greater than
2mm, and the joint misalignment exceeds the standard. It should not be corrected by
sanding, it should be cut and re-welded.
11）在未经打磨处理的情况下检查接头错边量，接头顶面不大于 0.2mm，轨
11
头侧面工作边不大于 0.2mm，轨脚边缘水平方向不大于 2mm，接头错边量超标的
接头不应使用打磨方法纠正，应切掉重新焊接。
12) For joints with unqualified right and wrong sides, the joints shall be cut off at
100mm positions on both sides of the weld, re-weld, and fill in the unqualified
welding head disposal record form.
12）对错边量不合格接头，应在焊缝两侧各 100mm 位置切掉接头，重新焊接，
并填写不合格焊头处置记录表。
3.4.2 Working tools and methods
3.4.2 作业工具及作业方法
1) Operation tools
1）作业工具
1.Mobile flash welding machine, 1m groove ruler and feeler or wave ruler
2.5Kw gasoline generator and lighting equipment
3. Flat shovel, small crowbar (60cm), railway crowbar, air pump and air pipe
4. Thin iron sheet, canvas, sun umbrella
5.Brush, metal splash
1.移动式闪光焊机、1m 凹槽尺和塞尺或波磨尺
2.5Kw 汽油发电机及照明设备
3. 扁铲、小撬棍（60cm）、铁路撬棍、气泵及气管
4.薄铁皮，帆布、太阳伞
5.毛刷、金属飞溅剂
2) Operation method
2）作业方法
1. Check the wrong side of the joint after pushing convex and before grinding
1.推凸后，打磨之前检查接头错边
a. Check with 1 meter groove ruler and feeler gauge
a.使用 1 米凹槽尺和塞尺检查
Use a 1-meter groove to detect the ruler's ruler and feeler gauge to check the
joint's misalignment. Measure and calculate the joint's misalignment at 15mm on each
side of the centerline of the weld, as shown in Figure 8;
使用 1 米凹槽检测直尺和塞尺检查接头错边，在焊缝中心线两侧各 15mm 的
位置测量并计算接头错边量，如图 8 所示；
b. Check with wave ruler
b.使用波磨尺检查
First calibrate the zero point, remove the zero calibration block and suck it flat
on one side of the positioning block, move the digital display probe to this side, press
the measuring rod to make the measuring end contact the zero point, the calibration is
fast, check the displayed value, when the displayed value When it deviates from the
zero point, you can touch the "0" button to restore the displayed value to "000.00" or
"0.00"
12
 首先标定零点，将零点标定块取下平整的吸在一边的定位块上，移动数显测
头到这边，按下测量杆使测量端部接触到零点标定快，检查示值，当示值偏离零
点时，可轻触“0”按钮，使示值恢复“000.00”或“0.00”
Place the measuring ruler on the steel rail to be measured, move the digital
display head to a position 15mm from the center line of the weld, repeatedly pull the
measuring rod to display the data on the display screen, press the measuring rod to
bring the end of the measuring rod into contact with the rail surface, and record The
indication value X on the digital display probe can obtain the wave wear value at this
point. Positive values are below the rail value and negative values are above
the rail value. Move the digital display probe to the other side of the weld at a distance
of 15mm from the center line of the weld, and measure the point wave wear value Y.
The amount of side deviation of the top surface of the rail is X-Y. The same method is
used to detect the amount of misalignment of the working edge on the side of the rail
head, and it is acceptable if it is not more than 0.2mm. The amount of lateral deviation
in the horizontal direction of the edge of the rail foot is not more than 2mm. Check
with a ruler and feeler to measure.
将测尺置于被测钢轨上，移动数显侧头到距离焊缝中心线 15mm 位置，反复
拉动测量杆使显示屏显示数据，按下测量杆，使测量杆端部与轨面接触，记录数
显测头上的示值 X，既得到该点的波磨值。正值为低于轨面值，负值为高于轨面
值。移动数显测头到焊缝另一侧距离焊缝中心线 15mm 处，测量该点波磨值 Y,钢
轨顶面错边量为 X-Y，数值不大于 0.2mm 为合格。用相同的方法检测轨头侧面工
作边的错边量，不大于 0.2mm 为合格。轨脚边缘的水 平方向错边量为不大于 2mm，
检查使用直尺和塞尺测量。
3.4.3 Safe operating procedures
3.4.3 安全操作规程
Ruler for testing

Joint wrong side

Rail working surface

Ruler for testing

Rail working surface Center line of weld Rail working surface

Joint misalignment=x-y(mm)

13
 1) Welding operators must pass the training and examination and hold a
certificate to work;
2) Welding workers must wear gloves, protective glasses, masks and other labor
protection supplies;
3) When entering the track, pay close attention to the coordination and
cooperation of the front and back processes;
4) During the welding process, welding operators should stick to their posts and
respond to emergency situations in a timely manner;
5) Maintain the welding machine in accordance with the instructions of the
welding machine;
6) Flammable, explosive and corrosive materials are strictly prohibited in the
welding machine room;
7) Clean the welding machine before work;
8) Fill in the equipment operation records for each shift, and check the work
records before each shift.
1)焊接作业人员必须经过培训考试合格，持证上岗；
2)焊接作业人员必须戴手套、防护眼镜、口罩等劳动保护用品；
3)进轨时，应密切注意前后工序的协调及配合；
4)焊接过程中，焊接作业人员应坚守岗位，及时应对紧急情况；
5)按照焊机说明书要求保养焊机；
6)焊机室内严禁放置易燃易爆和腐蚀性物品；
7)下班前清扫焊机卫生；
8)每班填写设备运转记录、每班工作前应查看上班记录。
3.5 Coarse grinding operation

14
 3.5 粗磨作业
5.5.1 Operating standards
5.5.1 作业标准
1) Coarse grinding parts: the non-working side of the welding head, the upper
and lower surfaces within 35mm from the edge of the rail foot, the edge of the rail
foot, and the bottom of the rail.
2) After rough grinding, the surface should be flat, smooth and smooth with the
base metal. The upper and lower edges of the rail foot edges should be rounded.
3) When grinding, it should be polished longitudinally along the direction of the
rail, and transverse grinding is not allowed.
4) During grinding, the grinding wheel should not jump sharply on the rails,
should not impact the rails, and there should be no burns on the polished surface of
the rails.
5) After rough grinding, check the surface quality of the joint, and there should
be no defects such as cracks and slag inclusions, otherwise the joint is cut and
re-welded.
6) Coarse grinding is not allowed to damage the rail base metal, and joints
should not be worn.
7) For individual joints that have excess projection allowances, rough grinding
can be used to smooth them, but special care should be taken not to damage the rail
base metal. When the protruding allowance exceeds the standard continuously, the
protruding tool should be adjusted or replaced.
1)粗磨部位：焊接接头轨头非工作边、距轨脚边缘 35mm 范围内的上下表面、
轨脚边缘，轨底。
2)粗磨后的表面应平整、光洁，与母材过渡圆顺，轨脚边缘上下棱角应倒成
圆角。
3)打磨时应沿钢轨方向纵向打磨，不允许横向打磨。
4)打磨时砂轮不应在钢轨上剧烈跳动，不应冲击钢轨，钢轨打磨表面不应出
现打磨灼伤。
5)粗磨后应检查接头表面质量，不应有裂纹、夹渣等缺陷，否则切掉接头重
新焊接。
6)粗磨不允许损伤钢轨母材，不应将接头磨亏。
7)对于推凸余量超标的个别接头，可以采用粗磨方式打磨平整，但应特别注
意不要损伤钢轨母材。推凸余量连续超标时，应调整或更换推凸刀具。
5.5.2 Working tools and methods
5.5.2 作业工具及作业方法
1) Operation tools
1）作业工具
Hand-held grinder

15
 手持砂轮机
2) Operation method
2）作业方法
When grinding a steel rail with a hand-held grinder, the operator stands on the
side of the hand-held grinder, holds the handle with his left hand, supports the back
end with his right hand, starts the grinder, and starts grinding.
用手持砂轮机打磨钢轨时操作者站在手持砂轮机一侧，左手握住手把，右手
托住后端，启动砂轮机，开始打磨。
3.5.3 Safe operating procedures
3.5.3 安全操作规程
1) The rough grinding operator should be familiar with the performance and
operation method of the grinder.
2) Check the condition of the grinder before operation. The grinder must be
installed with a leakage protector.
3) Gloves, glasses and masks must be worn during operation.
4) It is strictly forbidden to use uncovered grinder.
5) Be careful when grinding high-temperature joints, which may cause the
grinding wheel to break and fly out. No one or equipment should be in the dangerous
area.
1)粗磨操作人员应熟悉砂轮机的性能和操作方法。
2)作业前检查砂轮机状态，砂轮机必须安装漏电保护器。
3)作业时必须戴手套、眼镜、口罩。
4)严禁使用无罩砂轮机。
5)打磨高温接头时注意可能会导致砂轮破碎飞出，危险区域不应有人或设备。
3.6 Joint heat treatment
3.6 接头热处理
3.6.1 Operating standards
3.6.1 作业标准
1) Rail welded joints must be heat treated.
2) During the heat treatment of the welded joints, the rail joints shall be heated in
full section.
3) The temperature of the welding joint before heating should be lower than
500 ℃ (the surface of the rail head)
4) The heating temperature is 850-950 ℃, the heating temperature of the top
surface of the rail should not be higher than 950 ℃, and the heating temperature of
the rail foot should not be lower than 850 ℃.
5) Record the heating start temperature and the rail head and rail foot heating
temperature, and fill in the rail heat treatment station record form.
1）钢轨焊接接头必须进行热处理。
2）焊接接头热处理时应对钢轨接头进行全断面加热。

16
 3）加热前焊接接头温度应低于 500℃（轨头表面）
4）加热温度为 850-950℃，钢轨顶面加热温度不应高于 950℃，轨脚加热温
度不应低于 850℃。
5）记录加热起始温度及轨头、轨脚加热温度，填写钢轨热处理工位记录表。
3.6.2 Working tools and methods
3.6.2 作业工具及作业方法
1) Working tools: heat treatment equipment, thermometer
2) Operation method
1）作业工具：热处理设备、测温仪
2）作业方法
Heat treatment: The flame joint or induction heater is used to heat the welded
joint, and the heating temperature is measured with a thermometer.
热处理：加热使用火焰加热器或感应加热器对焊接接头进行加热，加热温度
使用测温仪测量。
The operation is performed according to the requirements of the equipment.
操作按设备使用要求进行。
The thermometer is used in accordance with the corresponding requirements.
测温仪按相应要求使用。
Note: It is strictly forbidden to use water to cool the joint after heat
treatment. In case of rain or snow, protective measures must be taken.
注意：热处理完毕后严禁使用浇水的方式进行冷却接头，如遇雨雪天气必
须采取防护措施。
3) The temperature measurement part is mainly the weld on the top surface of the
rail and the fillet on the bottom of the rail.
3）测温部位主要是轨顶面焊缝部位及轨底角焊缝部位。
3.6.3 Safe operating procedures
3.6.3 安全操作规程
1) Heat treatment operators must be trained and certified to work;
2) Operators should be familiar with the performance and operation methods of
the equipment;
3) Ensure that the equipment is in a normal condition and maintain the
equipment in accordance with the requirements of the equipment manual. The
management, use and maintenance of pressure vessels shall comply with relevant
regulations.
4) Adequate fire extinguishing equipment must be provided at the site, especially
oxygen and acetylene should be stored separately during heat treatment. It is strictly
forbidden to step on oxygen and acetylene gas pipes during heat treatment to prevent
gas backfire. The distance between oxygen and acetylene bottles during storage and
use should not be less than 6 meters to prevent fire or explosion accidents on site.
1）热处理作业人员必须经过培训，持证上岗；
17
 2）作业人员应熟悉设备的性能和操作方法；
3）保证设备状态正常，按照设备说明书要求保养设备。压力容器的管理、
使用和保养应遵守相关规定。
4）现场必须配备足够的灭火器材，尤其热处理作业时氧气、乙炔要分开存
放，热处理过程中严禁人员踩踏氧气、乙炔气管，防止气体回火。氧气、乙炔瓶
存放、使用时相隔距离不应小于 6 米，以防现场出现火灾或爆炸事故
3.7 Straightening of welded joints
3.7 焊接接头矫直作业
3.7.1 Operating standards
3.7.1 作业标准
1) After heat treatment of rail welding heads, straighten the joints with excessive
joint bending conditions. Straighten the joints in a cold state and measure the original
flatness of the joint before straightening.
2) Straightening methods should not be used to correct joint misalignment
1）钢轨焊头热处理后应对接头弯曲情况超标的接头进行矫直处理，矫直应
在冷态下进行，矫直前应测量接头原始平直度。
2）不应使用矫直的方法纠正接头错边
3.7.2 Working tools and methods
3.7.2 作业工具及作业方法
1) Working tools: straightening equipment, 1m rail flat gauge and feeler gauge
2) Operation method
1）作业工具：矫直设备、1m 钢轨平尺和塞尺
2）作业方法
1. For the use of straightening equipment, please refer to the instruction for
straightening equipment.
2. 1m rail flat and feeler
1.矫直设备使用方法见矫直设备使用说明。
2. 1m 钢轨平尺和塞尺
With the weld as the center within 1m, place a flat ruler on the longitudinal
centerline of the top surface, and hold one end of the ruler. If there is a gap between
the other end of the ruler and the top surface of the rail, the flatness of the joint is
upward. Ruler detects gap distance. If there is a gap between the middle of the ruler
and the top surface of the rail, the joint is a low joint and it needs to be cut and
re-welded. Place the flat ruler on the longitudinal side of the rail head at the end of the
rail at a length of 16mm from the top surface of the rail. Press and hold one end of the
ruler. If there is a gap between the other end of the ruler and the top surface of the rail,
the joint is unqualified and should be polished. If there is a gap between the middle of
the ruler and the top surface of the rail, use a feeler gauge to check the gap distance.
以焊缝为中心 1m 范围内，将平尺放在顶面纵向中心线上，按住尺子一端，

18
如果尺子另一端与钢轨顶面之间有间隙，说明接头的平直度是向上，用塞尺检测
间隙距离。如果尺子的中间与钢轨顶面之间有间隙，说明接头是低接头，需切掉
重焊。将平尺放在轨端的轨头侧面工作上距轨顶面 16mm 处的纵向线上，按住尺
子一端，如果尺子另一端与钢轨顶面之间有间隙，说明接头不合格，应继续打磨。
如果尺子的中间与钢轨顶面之间有间隙，用塞尺检测间隙距离。
Straighten the test results to determine that the final results meet the
requirements of the iron standard.
调直检测结果以最终结果满足铁标要求确定。
3.7.3 Safe operating procedures
3.7.3 安全操作规程
Straightening equipment uses hydraulic pressure as the straightening power, and
the corresponding operating regulations should be observed when using it.
矫直设备使用液压作为矫直动力，使用时应遵守相应的操作规程。
3.8 Fine grinding of welded joints
3.8 焊接接头精磨作业
3.8.1 Operating Standards
3.8.1 作业标准
1) The temperature of the joint should be lower than 50 ℃ before fine grinding.
2) After finishing grinding, the contour of the rail head should be maintained,
and no mechanical or thermal damage should be caused to the welded joint or the rail.
3) The length of fine grinding should not exceed the limit of 450mm on each side
of the centerline of the weld. The shorter the grinding length is, the better; the
grinding depth of the base metal should not exceed 0.5mm (excluding the protruding
allowance).
4) The flatness of the joint after fine grinding should meet the following
requirements: within 1m from the center of the weld, the flatness of the top surface of
the rail is δ + (0.1-0.4mm, set the arch amount of 0.1-0.2); The flatness of the working
side is 0.2mm (recessed). δ is the settlement amount, which should be determined
according to the long rail simulation welding test.
5) The surface unevenness of the joint after fine grinding should meet: the
surface unevenness within 100mm of the two sides of the centerline of the weld is not
greater than 0.2mm.
6) Check the surface of welded joints for cracks, obvious indentations, scratches,
bumps and other injuries.
8) The method of shape adjustment should not be used to correct the deviation of
straightness exceeding the standard and the wrong side of the joint exceeding the
standard.
9) After the joints are finely ground after welding, fill in the rail fine grinding
record form.
1）精磨前接头温度应低于 50℃。
2）精磨后应保持轨头轮廓形状，不应使焊接接头或钢轨产生任何机械损伤

19
或热损伤。
3）精磨长度不应超过焊缝中心线两侧各 450mm 限度，打磨长度越短越好；
母材打磨深度不超过 0.5mm（不包括推凸余量）
。
4）精磨后接头平直度应满足：以焊缝为中心 1m 范围内，钢轨顶面的平直度
为δ+（0.1-0.4mm,设置 0.1-0.2 的上拱量）；轨头侧面工作边的平直度为 0.2mm
（凹进）
。δ为沉降量，应根据长轨模拟焊接试验确定。
5）精磨后接头表面不平度应满足：焊缝中心线两侧各 100mm 范围内表面不
平度不大于 0.2mm。
6）检查焊接接头表面，应无裂纹、明显压痕、划伤、碰伤等伤损。
8）不应使用外形精整的方法纠正超标的平直度偏差和超标的接头错边。
9）焊后接头精磨合格后，填写钢轨精磨记录表。
3.8.2 Work tools and work methods
3.8.2 作业工具及作业方法
1) Working tools: copy sander, electronic flat ruler, 200mm flat ruler
2) Operation method
1）作业工具：仿型打磨机、电子平直尺、 200mm 平尺
2）作业方法
1.Copy sander
1. 仿型打磨机
Place the grinder on the steel rail that needs to be polished, insert the power plug
firmly into the power socket, and turn the vertical feed handle counterclockwise so
that the grinding wheel does not contact the top surface of the rail that needs to be
polished. Press the switch and the grinding wheel rotates without load, evenly. Turn
the vertical feed handle clockwise to make the grinding wheel move towards the top
surface of the rail until sparks come into contact with the top surface of the rail to be
polished. At the same time, when the horizontal roller is close to the top surface of the
rail, the handle is moved back and forth to achieve uniform control. The feed of the
grinding wheel is generally within 0.2mm each time. Check for abnormalities and the
thickness of the wear scars. The polished rail surface must not show blue or obvious
scratches. When the handle is pulled, the body is gradually inclined inward along the
cross section of the rail, and the lateral grinding range of the rail top is enlarged by the
control of the guide rollers of the grinder, and is polished from the center line of the
rail top to the inner corner of the rail head. Loosen the grinding frame locking
mechanism, make the grinder turn 90 ° inward along the rail transverse direction, and
pull the grinder back and forth to grind the inner side of the rail. Turn the handle to
release the grinding wheel from the state of contact with the rails. Press the power off
switch to stop the grinding machine. After resetting the grinder, lift the grinder to
rotate it horizontally 180 °. Place the rail on the rail and repeat the above operation to
polish the top surface of the rail. Part and the outer side of the rail head until the
grinding meets the required standards.
20
 将打磨机放置在需要打磨的钢轨上，电源插头牢固插入电源插座上，逆时针
转动垂直进给手柄，使砂轮与需打磨的轨顶面不接触，按下开关，砂轮空载旋转，
均匀的顺时针转动垂直进给手柄，使砂轮向轨顶面移动，直至接触待打磨的轨顶
面打出火花，同时牵动手柄在水平滚轮紧靠轨顶面的情况下，使机体左右往复移
动，均匀控制砂轮的进给量，一般每次 0.2mm 以内，检查有无异常和磨痕的粗细，
打磨后的钢轨表面不得呈蓝色或明显划痕。牵动手柄时，使机体沿钢轨横断面方
向向内侧逐渐倾斜，凭借打磨机导向滚轮的控制扩大轨顶横向打磨范围，从轨顶
中心线打磨至轨头内侧圆角处。松开打磨机架锁定机构，使打磨机沿钢轨横断方
向向内侧转 90°，牵引打磨机往复打磨钢轨的内侧面。转动手柄使砂轮退出后
脱离与钢轨接触状态，按下断电开关，砂轮机停止转动，将打磨机复位后抬起打
磨机水平旋转 180°，放置钢轨上重复上述动作既可打磨轨顶面剩余部分和钢轨
头部的外侧面，直至打磨达到规定标准。
2. Use a 200mm square ruler to check the surface unevenness of the joint. Place
the flat ruler on the top surface of the rail, within 100mm on each side of the center
line of the weld. Use a feeler gauge to check the gap distance between the flat ruler
and the rail.
2. 用 200mm 平尺检查接头表面不平度。将平尺放在钢轨顶面，焊缝中心线
两侧各 100mm 范围内，用塞尺检查平尺与钢轨之间的间隙距离，不大于 0.2mm
为合格。
3 ． Use an electronic ruler to measure the flatness of the connector. Within 1m
from the center of the weld, the flatness of the joint surface is δ + (0-0.2mm), the
working side of the rail head is 0.2mm (recessed).
3．使用电子平直尺测量接接头平直度。以焊缝为中心 1m 范围内，接头表面
平直度为δ+（0-0.2mm），轨头侧面工作边为 0.2mm（凹进）
。
3.9 Welded joint inspection
3.9 焊接接头探伤作业
3.9.1 Working tools and methods
3.9.1 作业工具及作业方法
1) Working tools: flaw detector
2) Operation method
1）作业工具：探伤仪
2）作业方法
1. System calibration
1．系统校准
According to TB / T 2658.21-2007 test method, use standard test blocks (CS-1-5,
CSK-IA) to test the performance of the ultrasonic flaw detector (vertical linearity,
horizontal linearity, sensitivity margin) and the performance of the probe (K value,
Cutting edge), and fill in the "Performance Test Records of Ultrasonic Flaw Detectors
21
and Probes".
依据 TB/T 2658.21-2007 测试方法，用标准试块（CS-1-5、CSK-IA）测试超
声波探伤仪的性能（垂直线性，水平线性，灵敏度余量）及探头的性能（K 值，
前沿） ，并规范填写《超声波探伤仪及探头性能测试记录》 。
According to the TB / T 2658.21-2007 calibration method, the contrast detection
block (GHT-1, GHT-5) is used to calibrate the flaw detection sensitivity (making
distance-amplitude curve, AVG or DGS curve, etc.). The dual probe method uses the
GHT-1 test block. The single-probe method GHT-5 test block, and the "Regulation
Record of Ultrasonic Flaw Sensitivity of Rail Welding Joints" shall be filled in as
required.
依据 TB/T 2658.21-2007 校准方法，用对比试块（GHT-1、GHT-5）校准探伤
灵敏度（制作距离-波幅曲线、AVG 或 DGS 曲线等）
，双探头法使用 GHT-1 试块，
单探头法 GHT-5 试块，并规范填写《钢轨焊接接头超声波探伤灵敏度校准记录》 。
2. Flaw detection
2．探伤扫查
After the state of the flaw detection surface meets the requirements, an ultrasonic
probe is used for scanning.
探伤检测面的状态处理达到要求后，使用超声波探头进行扫查。
a. Double probe scanning:
a.双探头扫查：
K0.8 ～ K1 probes perform tandem scanning from the tread to the rail waist
and its extended parts; K0.8 ～ K2 probes perform K-scan from the rail head side;
K0.8 ～ K1 probes K-scan from the bottom of the rail facing the bottom of the rail.
K0.8～K1 探头从踏面对轨腰及其延伸部位进行串列式扫查；K0.8～K2 探头
从轨头侧面对轨头部位进行 K 型扫查；K0.8～K1 探头从轨底两侧面对轨底部位
进行 K 型扫查。
b. Single probe scanning:
b.单探头扫查：
K≥2 S-wave probe scans the probe from the tread or the side of the rail head and
from the bottom of the rail to the bottom of the rail; K0.8 ～ 1 S-wave probe scans
the rail waist to the bottom of the rail from the tread; For aluminized welds, a 0 °
probe is used to scan from the rail head to the rail head, the rail waist, and the rail
bottom.
K≥2 横波探头从踏面或轨头侧面对探头进行扫查和从轨底斜面上对轨底部
位进行扫查；K0.8～1 横波探头从踏面上对轨腰直至轨底进行扫查；对于铝热焊
焊缝，另加 0°探头从轨头踏面对轨头、轨腰直至轨底进行扫查。
c. When detecting flaws in aluminous welds, the scanning range should be the
full width of the weld.
d. Different types of flash welding and aluminum heat welding have different
types of defects, and appropriate methods should be used for flaw detection.
22
 e. When it is impossible to confirm the reflection echo caused by the shapes such
as edges and corners, the edges and corners should be ground and then explored, but
care should be taken not to exceed the limit.
c.铝热焊焊缝探伤时，扫查范围应遍及焊缝全宽度。
d.闪光焊、铝热焊的焊接形式不同，缺陷类型不同，应采用相适应的方法进
行探伤。
e.对可能是棱角等外形造成的反射回波而不能确认时，应将棱角打磨后再探，
但注意不应打磨超限。
3. Defect determination :.
3.缺陷判定：。
a. When the 0 ° probe flaw detection of aluminous welding is used, the bottom
wave of the weld is 16dB lower than the normal bottom wave or more, or the
following defects occur in the weld, the weld shall be rejected and the welding shall
be re-welded.
b. Dual probe flaw detection
Bottom angle of rail (20mm) ≥3-6dB flat bottom hole equivalent
Other parts ≥φ3 flat bottom hole equivalent
c. Shear wave single probe flaw detection
Rail head and rail waist ≥φ3 long horizontal hole equivalent
Rail bottom ≥φ4 vertical hole equivalent
Rail bottom angle (20mm) ≥φ4-6dB vertical hole equivalent
d.Aluminum welding 0 ° probe ≥φ5 long horizontal hole equivalent
e. There are planar defects in the weld.
f. The defect equivalent is 3dB or less than the above requirement, but the
extension length is greater than 6mm.
a.铝热焊 0°探头探伤时焊缝底波比正常底波低 16dB 及以上或焊缝出现以
下缺陷时，焊缝判废，应重新焊接。
b.双探头探伤
轨底角部位（20mm） ≥φ3-6dB 平底孔当量
其它部位 ≥φ3 平底孔当量
c.横波单探头探伤
轨头和轨腰 ≥φ3 长横孔当量
轨底 ≥φ4 竖孔当量
轨底角（20mm） ≥φ4-6dB 竖孔当量
d.铝热焊 0°探头 ≥φ5 长横孔当量
e.焊缝中存在平面状缺陷。
f.缺陷当量比上述规定低 3dB 或以内，但延伸长度大于 6mm。
3.9.2 Safe operating procedures
3.9.2 安全操作规程
23
 1) Flaw detection personnel should be familiar with the performance and
operation methods of the equipment. Flaw detection personnel should hold the
technical qualification certificate of level Ⅱ and above issued by the technical
qualification appraisal committee of the non-destructive testing personnel of the
railway department, and be able to work independently after receiving the technical
training of rail weld detection.
2) Before each shift, the standard test block is used to test the flaw detector and
probe and fill in the test records. The contrast test block is used to calibrate the flaw
detection sensitivity and fill in the calibration records. Test and calibration records
should be properly kept.
3) Ultrasonic flaw detection shall be performed on each joint, and records and
data analysis shall be made to make a correct judgment on whether there is a flaw in
the flaw detection of the rail weld. And fill in the "ultrasonic flaw detection records of
railway rail welding joints" in detail, the record information should include at least the
construction unit, welding type, joint number, equipment, defect data, flaw detection
results, treatment opinions, etc. Flaw detection records shall be properly kept in
accordance with relevant regulations.
4) If the welding seam is damaged beyond the standard, the on-site personnel
shall be required to saw and re-weld the joint and perform the inspection again. Have
a good inspection record sheet at the end of the inspection.
1)探伤人员应熟悉设备的性能和操作方法。探伤人员应持有铁道部门无损检
测人员技术资格鉴定考核委员会颁发的Ⅱ级及以上级别的技术资格证书，并经过
钢轨焊缝探伤技术培训方能独立上岗作业。
2)每班作业前，应用标准试块测试探伤仪及探头并填写测试记录，用对比试
块校准探伤灵敏度并填写校准记录。测试、校准记录应妥善保存。
3)应对每个接头进行超声波探伤检查，做好记录与数据分析，对钢轨焊缝的
探伤是否存在缺陷做出正确的判断。并详细填写《铁路钢轨焊接接头超声波探伤
记录》，记录信息应至少包括施工单位、焊接类型、接头编号、仪器设备、缺陷
数据、探伤结果、处理意见等。探伤记录应按有关规定妥善保存。
4)如果出现焊缝有超标伤损，就要要求现场人员对接头锯切重新焊接，再次
进行探伤工作。在探伤结束后要好探伤记录表。
3.10 Line Recovery
3.10 线路恢复
3.10.1 Operating standards
3.10.1 作业标准
Install the removed buckle fittings. The type, specifications and dimensions of
the buckle fittings should be the same as before the removal. There must be no
missing or wrong installation.
安装好已经卸掉的扣配件，扣配件的类型、规格、尺寸应与拆卸前相同。不
得出现漏装、错装。
24
 3.10.2 Working tools: lifter, T-wrench
3.10.2 作业工具：起道器、丁字扳手
IV. Precautions
四、注意事项
4.1 The long rails in the interval can be composed of several unit rail sections,
which generally take 1000 ~ 2000m, and the shortest must not be shorter than 200m.
4.1 区间长轨条可由若干单元轨节组成，一般取 1000~2000m，最短不得短
于 200m。
4.2 Each group of seamless turnouts and the steel rails locked at the front and
back are counted as one unit rail section.
4.2 每组无缝道岔及其前后一次锁定的钢轨按一个单元轨节计。
4.3 Insulated joints use cemented insulated joints. The rails should be of the
same rail type and same steel type as the adjacent rails; the insulated joints of the left
and right strands of rails should be laid opposite each other, and the end of the
insulated joint plywood should not be less than 100mm from the edge of the sleeper.
4.3 绝缘接头采用胶结绝缘接头，其钢轨应与相邻钢轨同轨型、同钢种；左
右两股钢轨的绝缘接头应相对铺设，且绝缘接头夹板端头距轨枕边缘不宜小于
100mm。
4.4 The start and end points of the unit track section should not be set in the
transition zone of different track structures and the scope of the base transition zone of
different lines.
V. Safety and environmental requirements
五、安全及环保要求
5.1 Construction operations must be carried out in accordance with relevant
regulations. Construction workers shall maintain a safe distance during collective
operations to prevent accidents such as bumps, injuries and injuries.
5.1 施工作业必须按照有关规定进行。施工人员在集体作业时要保持安全间
距，防止发生人员碰伤、砸伤、撞伤事故。
5.2 The operator must be trained and qualified before he can work. The operator
must be familiar with the "Electrical Safety Rules" before operation.
5.2 操作者必须接受培训合格后方可上岗操作。操作者在操作前必须熟悉
《电气安全规则》。
5.3 When operating the welding machine, you must wear thick gloves, insulated
shoes, and protective glasses.
5.3 操作焊机时必须戴厚手套，穿绝缘鞋，戴防护眼镜。
5.4 The operator must strictly follow the operating procedures and technical
requirements and compare with the "welder operation rules"
5.4 操作者必须严格按照操作程序和技术要求，对照《焊机操作规则》
5.5 Power distribution boxes, electric machinery, and hand-held power tools
must be installed with earth leakage protectors and grounding and zero-connection
devices in accordance with regulations. "Protection" requires wiring and use.
5.5 配电箱、电动机械、手持电动工具，必须按规定安装漏电保护器和接地、
25
接零装置，漏电保护器应符合 GB6829-86 的要求，严格按“一机、一箱、一闸、
一保护”要求进行布线和使用。
5.6 Civilized construction
5.6 文明施工
Set up site signs indicating the project name, scope, start and finish time, person
in charge of construction, and person in charge of technology. Set up supervision,
report telephone numbers and mailboxes, and accept supervision. Operators must
keep the bridge deck clean and tidy. Set up eye-catching safety warning signs and
safety slogans at the construction site, and install electric power facilities on-site for
construction in a standardized, safe, reliable, and safe and civilized standard
construction site.
设置工点标牌，标明工程项目名称、范围、开竣工时间、施工负责人、技术
负责人。设置监督、举报电话和信箱，接受监督。作业人员必须保持桥面整洁，
禁止乱扔杂物。施工现场设置醒目的安全警示标志、安全标语，现场施工用电设
施安装规范、安全、可靠、建设安全文明标准工地。
5.7 Environmental protection measures
5.7 环境保护措施
The construction site should conduct environmental management on the site in
accordance with the requirements of the Environmental Management System
Requirements and Use Guide (ISO14001). The discharge and treatment of pollutants
generated during the construction shall comply with the current national and local
regulations on environmental protection and the requirements of construction
drawings. The storage of various materials at the construction site must be
standardized and orderly. Machinery and equipment and construction techniques that
meet environmental requirements should be used. Arrange construction time
reasonably to reduce noise disturbance to the people.
施工现场宜按《环境管理体系要求及使用指南》
（ISO14001）规定对现场进
行环境管理。施工期间所产生的污染物排放和处理应符合国家和地方有关环保的
现行法规规定和施工图要求。施工现场各种材料的存放必须规范、有序。应使用
符合环保要求的机械设备和施工工艺。合理安排施工时间，减少噪声扰民。

26
 Stress release and locking of seamless lines

无缝线路应力放散及锁定
I. Stress release
一、应力放散
1.1 Construction process
1.1 施工工艺
The stress release is to remove the fasteners of the unit rail section, release the
constraint, lift the roller, and release the temperature force accumulated in the unit rail
section by means of the roller, rail puller, rail impactor, small hammer and other tools,
and then drop the groove. , Fasten the fasteners to ensure that the rails reach zero
stress under the locked rail temperature. There are two types of release stress and line
lock: drum release method and comprehensive release method. According to the
measured rail temperature judgment, when the rail temperature is within the designed
locked rail temperature range, the "roll-down release method" is adopted, and when
the rail temperature is below the locked rail temperature range, the "comprehensive
release method" is adopted. After the line is released by stress and welded and locked,
a seamless line is formed.
应力放散是拆除单元轨节的扣件，解除约束，抬上滚筒，通过滚筒、拉轨器、
撞轨器、小锤等工具，使积累在单元轨节内的温度力得到释放 ,然后落槽，上好
扣件锁定,保证钢轨在锁定轨温下达到零应力状态。放散应力与线路锁定有滚筒
放散法与综合放散法两种。根据测量轨温判断，当轨温在设计锁定轨温范围内时
采用“滚简放散法”，当轨温在锁定轨温范围以下时采用“综合放散法”
。线路经
应力放散和焊接锁定后形成无缝线路。
The process flow of stress release and lock welding construction is shown in the
figure below：

27
 Remove fasteners, support rollers

Rail impact, stress release

Measure the rail temperature, draw the

rail displacement displacement mark

Calculate stretch amount, saw rail

Unit rail section stretch and lock

Lock welding

Set the unit track section displacement

应力放散、锁定焊接施工工艺流程见下图：

拆卸扣件，支垫滚筒

撞轨，应力放散

测轨温，画钢轨拉伸位移标记

计算拉伸量，锯轨

单元轨节拉伸、锁定

锁定焊

设置单元轨节位移观测标记

1.2 Construction method

1.2 施工方法
There are two methods for stress release construction. The first method is called
the roller release method (the roller cooperates with the impact rail), that is, the actual

28
rail temperature is within the design locked rail temperature range, and a roller is
placed under the rail during release; the rail is hit with a hammer. , Make the rails
freely expand and contract, after the rails have fully rebounded, that is, the internal
stress of the rails reaches zero stress and then quickly lock the line; the second method
is called the comprehensive release method (roller combined with stretching and
collision with the rail), that is, the actual rail temperature is lower than When the
lower limit of the rail temperature is locked, the underside of the rail is rolled down,
and one end of the unit rail section to be released is welded to the line that has been
released and locked. The seamless line provides the reaction force, and one end is
installed with a rail tensioner. The basic formula ∆L = αL∆t calculates the stretch
amount of the unit rail section. When the unit rail section is in a freely retractable
state at the current construction temperature, mark the displacement zero point, and
then use the rail puller to stretch the unit rail section. Until the calculated amount of
stretching, pay attention to the zero return to zero and the displacement of the
temporary displacement observation point is linearly proportional. When the
difference between the calculated value and the theoretical value is not more than
3mm, the rail falls and the line is immediately locked.
应力放散施工有两种放散方法，第一种称为滚筒放散法(滚筒配合撞轨)，即
实际轨温在设计锁定轨温范围内，放散时在钢轨下加垫滚筒；利用锤击敲打钢轨，
使钢轨自由伸缩，等钢轨充分回弹后，即钢轨内应力达到零应力然后迅速锁定线
路；第二种方法称为综合放散法(滚筒结合拉伸配合撞轨)，即实际轨温低于锁定
轨温下限值时，钢轨下垫上滚简，将要放散的单元轨节一端与已放散锁定的线路
焊接，靠无缝线路提供反力，一端安装钢轨拉伸器，根据当时轨温根据基本公式
∆L=αL∆t 计算出单元轨节的拉伸量，等单元轨节在当时的施工温度下处于自由伸
缩状态时,进行位移零点标记，再用拉轨器将单元轨节拉伸至计算出的拉伸量，
并注意零点归零及临时位移观测点的位移量成线性比例。当与理论计算值相差不
大于 3mm 时，钢轨落槽，即刻锁定线路。
Selection of the release method: In order to make the stress release work of the
seamless line continuous, it is selected according to the site weather and temperature
conditions. When the rail temperature is lower than the design-locked rail temperature,
a comprehensive release method is adopted; when the rail temperature meets the
design-locked rail temperature, a rolling reduction method is used.
放散方法的选用：为使无缝线路应力放散工作连续进行，根据现场天气、气
温情况选用。当轨温低于设计锁定轨温时采用综合放散法；当轨温满足设计锁定
轨温时采用滚简放散法。
1.3 Roller release method
1.3 滚筒放散法(滚简配合撞轨)

29
 1.3.1 Process flow
1.3.1 工艺流程
Preparation for construction— → Removal of fasteners— → Mat roller— →
Rail temperature measurement— → Rail knocking (collision rail) one → Rail
rebound one Pieces— → mark for displacement observation
施工准备—→拆扣件—→垫滚筒—→测轨温—→敲轨（撞轨）一→钢轨反弹
一→拆滚简一→上扣件(隔二上一)一→上完所有扣件—→作位移观测标记
1.3.2 Construction steps
1.3.2 施工步骤
(1) Before the line stress is released, a displacement observation pile is set up
and numbered.
(2) Within the stress range of release and adjustment (1500 meters), loosen all
sleeper fasteners.
(3) Put a splint on one end where the buffer zone and the long rail are connected;
leave the neutral position at the other end with the long rail joint (wrong the two long
rail joints); and measure the rail temperature.
(4) Raise the high and long steel rail, pad it into the drum every 10-12.5 meters,
and shovel off the rubber pad at the bottom of the rail.
(5) Install the rail collision fixture (1 / 500m), and hit the fixture with the rail
collision device to make the long rail into a free state. First tighten the rail fasteners
connected to the buffer section (screws in the 37.5m range). Check whether the
displacement per 100 meters is in place; otherwise, it will continue to hit the rails to
make the displacement reach the standard requirements.
(6) Remove the rail-clamping fixture, remove the rolling rail, and the long rails
fall into grooves; fasten a fastener of each sleeper.
(7) Complete the fasteners and mark the zero point of the displacement
observation.
(8) Measure the rail temperature immediately after the release of the single
strand, and fill in the "Record of stress release and lock operation of the unit rail
section". When the temperature difference between the left and right strands does not
exceed 3 ° C, another long rail release lock operation is performed.
(9) Repeat the above steps to complete the release of the rail section of this unit.
(10) Weld and lock the long steel rail to be released and the already released long
steel rail.
(11) When the rail temperature does not exceed 5 ° C, the above steps perform
the stress release of the next unit rail section.
(1)在线路应力放散前，设置位移观测桩，并进行编号。
(2)在放散与调整的应力范围内(1500 米),松开所有枕木扣件。
(3)在缓冲区与长轨条连接处的一端上好夹板；另一端与长钢轨接头处留出
空挡（将两条长轨条接头相错）；同时测出轨温。

30
 (4)起高长钢轨，每 10-12.5 米垫入滚筒，铲下轨底胶垫。
(5)安装撞轨夹具(1 个/500 米)，用撞轨器撞击夹具，使长轨成自由状态。首
先将与缓冲区一段连接的钢轨扣件拧紧(37.5 米范围螺栓拧紧)。检测每 100 米的
位移量是否到位；否则继续撞轨，使位移量达到标准要求。
(6)撤下撞轨夹具,取下滚简,长轨条落槽；每隔一根轨枕上紧一根轨枕的扣件。
(7)补齐扣件，标记位移观测“零”点。
(8)单股放散结束后立即测定轨温，填写“单元轨节应力放散及锁定作业记
。在左右股温差不超过 3℃时，再进行另一股长轨放散锁定作业。
录”
(9)重复以上步骤步完成此单元轨节的放散工作。
(10)将待放散的长钢轨与已放散长钢轨进行焊接锁定。
(11)在轨温不超过 5℃时，以上步骤，进行下一单元轨节应力放散。

31
 Determine the release length

Relax fastener

Drum into the drum

Measuring rail
temperature
Within the temperature
range of the design lock
rail
Impact rail

No
Whether there is

Yes

Rail drop, mounting

Measurement
record
Set displacement Lock rail
temperature

Read and record initial

End

Process flow chart of roller release method

32
 确定放散长度

放松扣件

垫入滚筒

测量轨温

在设计锁定轨温范围内

撞击钢轨

否
是否出现反弹

钢轨落槽，安装扣件
测量记录
锁定轨温

设位移观测标记

读取并记录初始位移

结束

滚筒放散法工艺流程图

1.4 Comprehensive release method

1.4 综合放散法(滚简结合拉伸配合撞轨)
1.4.1 Process flow
1.4.1 工艺流程
Preparation for construction— → Removal of fasteners— → Mat roller— →
33
Rail temperature measurement— → Installation of rail impactor— → Installation of
pretensioner for pre-stretching to make the rails in a freely retractable state— →
Measurement of rail temperature to calculate the amount of stretching at each point —
→ Set a temporary observation point mark every 100 meters → Stretch and use a rail
impactor to observe and observe the displacement of each point— → After the
displacement of each point meets the requirements for dispersal, unwind and roll one
→ Upper fastener (separate from two to one) ） — → Finish all fasteners— → Make
displacement observation mark
施工准备—→拆扣件—→垫滚筒—→测轨温—→安装撞轨器—→安装拉伸
器预拉伸敲击使钢轨处于自由伸缩状态一→测轨温计算各点拉伸量—→每隔
100 米设 1 个临时观测点标记一→拉伸并用撞轨器撞击、观测各点位移量—→各
点位移达到放散要求后拆滚简一→上扣件（隔二上一）—→上完所有扣件—→作
位移观测标记。
1.4.2 Construction method
1.4.2 施工方法
(1) Before the line stress is released, a displacement observation pile is set up
and numbered.
(2) Within the released and adjusted stress court (1500 meters), loosen all sleeper
fasteners.
(3) Put a splint on one end where the buffer zone and the long rail are connected;
leave the neutral position at the other end with the long steel rail joint (one long rail is
stretched to one section separately); measure the rail temperature at the same time. A
section of a long rail is fixed, and a rail stretcher cooperates with a rail impactor to
stretch the other end. Before stretching, adjust the rail gap of the buffer zone into
place; tighten the fixed section at one end (tighten the bolt in the 37.5 meter range). (4)
Raise the high and long steel rail, pad it into the drum every 10-12.5 meters, and
shovel off the rubber pad at the bottom of the rail.
(5) Stretching is performed, while the stretcher is functioning, the fixture is
struck with a rail impactor to promote the free expansion and contraction of the long
steel rail under vibration.
(6) When the long rail is no longer telescopic, accurately measure the actual
telescopic amount and temperature of the long rail, check whether the displacement at
each point is in place to check whether the stretching is uniform; if the displacement
at one end of the stretching is in place, and The amount of displacement away from
the stretcher is not yet in place. Use the rail impactor to continue the impact to urge it
into place.
(7) After the displacement of each measuring point is in place, withdraw the
drum and drop the long rail; after the sleeper fasteners in the stretch section of 50-100
meters close to the stretcher are all tightened, remove the stretcher.
(8) Complete the fasteners, remove the rail puller, and mark the "zero" point of
the displacement observation.

34
 (9) Measure the rail temperature immediately after the release of the single
strand, and fill in the "Record of stress release and lock operation of the unit rail
section". When the temperature difference between the left and right strands does not
exceed 3 ° C, another long rail release lock operation is performed.
(10) Repeat the above steps to complete the release of the rail section of this unit.
(11) Weld and lock the long steel rail to be released and the long steel rail that
has been released.
(12) When the rail temperature does not exceed 5 ° C, the above steps perform
the stress release of the next unit rail section.
(1)在线路应力放散前，设置位移观测桩，并进行编号。
(2)在放散与调整的应力苑围内(1500 米)，松开所有枕木扣件。
(3)在缓冲区与长轨条连接处的一端上好夹板；另一端与长钢轨接头处留出
空挡(一根长轨单独向一段拉伸)；同时测出轨温。固定长轨条的一段，钢轨拉伸
器配合撞轨器拉伸另一端。拉伸前，把缓冲区的轨缝调蹩到位；拧紧一端的固定
段(37.5 米范围螺栓拧紧)。 (4)起高长钢轨，每 10-12.5 米垫入滚筒，铲下轨
底胶垫。
(5)实施拉伸，在拉伸器发挥作用的同时，用撞轨器撞击夹具，促使长钢轨
在振动下自由伸缩。
(6)在长钢轨不再伸缩时，精确测量长钢轨的实际伸缩量和轨温，检查各点
的位移量是否到位，以检验拉伸是否均匀；如拉伸一端的位移量已经到位，而远
离拉伸器的位移量尚未到位，使用撞轨器继续撞击，促其到位。
(7)各测点的位移量均已到位后，撤出滚筒，落下长轨条；靠近拉伸器 50-100
米拉伸段轨枕扣件全部上紧后，撤除拉伸器。
(8)补齐扣件,卸下拉轨器，标记位移观测“零”点。
(9)单股放散结束后立即测定轨温，填写“单元轨节应力放散及锁定作业记
录”
。在左右股温差不超过 3℃时，再进行另一股长轨放散锁定作业。
(10)重复以上步骤步完成此单元轨节的放散工作。
(11)将待放散的长钢轨与已放散长钢轨进行焊接锁定。
(12)在轨温不超过 5℃时,以上步骤，进行下一单元轨节应力放散。

35
 确定放散长度

放松扣件

垫入滚筒

测量轨温

低于设计锁定轨温

撞击钢轨使之达到自由状态

计算拉伸量

设拉伸位移观测标记

拉伸钢轨 同时撞击

继续撞击

不均匀
读取位移

均匀

钢轨落槽，安装扣件
测量并记录
锁定轨温
设位移观测标记

读取并记录初始位移

结束

综合放散法工艺流程图
36
Process chart of comprehensive release method

Determine the release length

Relax fastener

Drum into the drum

Measuring rail
temperature
Below Design Lockout Rail
Temperature
Hit the rail to make it free

Calculate the amount

of stretch
Set the tensile displacement
observation mark

Stretch rail Simultaneous impact

Keep hitting

Uneven
Read displacement

Unifor
m
Rail drop, mounting fasteners
Measure and record
Lock rail temperature
Set displacement observation

Read and record initial

End

37
 Unit rail joint stress release and lock operation record
Line Interval Long track number
Start and Full length The weather
end
mileage
Release Lock time Start and end time
date
Release Lock rail
method temperature
Conversion of locked rail 0 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1
temperature after stretching （℃） 0 1 2 3 4 5
Measuring point
number
Left Planned release
Technica stock (mm)
l status Actual release
of the amount (mm)
actual Right Planned release
release stock (mm)
line Actual release
amount (mm)

Line Left stock

situati Right stock
on

38
 after
release 单元轨节应力放散及锁定作业记录
线别 区间 长轨编号
起止Note 长轨全长 Date
天气of Year 月 Day
里程 filling:
放散 锁定时间 作业起止时间
日期
放散 锁定轨温
方法
拉伸后换算锁定轨温（℃） 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
测点编号
左股 计划放散量
（mm）
实际 实际放散量
放散 （mm）
地段 右股 计划放散量
线路 （mm）
技术 实际放散量
状态 （mm）

39
 放散后线 左股
路情况 右股

备注 填表日期： 年 月 日

40
 II. People organization
二、人员组织
When using the rail collision method, a set of full-time shelf teams and a team
leader are set up. The human organization is as follows:
采用撞轨法施工时，设置一组专职架子队，并设一名队长。人力组织如下：
1.Dispersion group: There is a release group every 150 meters, with 5 people in
each group. The release group is responsible for loosening the loose fasteners,
removing the rubber pads, placing the rollers, assisting in hitting the rail, and
responsible for locking. Configure an electric wrench to tighten the device.
1、放散组: 每一百五十米设置一放散小组，每小组 5 人。放散组负贲松扣
件、铲下胶垫、放置滚筒、协助撞轨、负责锁定。配置一台电动扳手紧固设备。
2. Rail collision group: There is one rail collision group every 500 meters, and
five people in each group are responsible for crashing the rail collision device, and
cooperate with the release group to prepare.
2、撞轨组: 每 500 米设 1 组撞轨组，每小组 5 人，负责撞击撞轨器，配合
放散组做好准备工作。
3. Longkou Group: 6 people, responsible for rail stretching. Equipped with a
stretcher, rail saw, generator and other equipment.
3、龙口组: 6 人,负责钢轨拉伸。配置一台拉伸器、锯轨机、发电机等设备。
4. Protection team: Set up guards and one liaison station in accordance with the
operation near the business line.
4、防护组: 按照临近营业线作业设置防护员，驻站联络员 1 人。
5. Technical group: responsible for calculating, measuring the amount of
radiation, measuring the temperature of the rail, and recording the technical data of
the radiation.
5.技术组:负责计算、测量放散量、测量轨温、记录放散技术数据。
III. Construction equipment
三、施工机具
Construction equipment table
Serial number Name Unit Quantity model
Rail sawing
1 Station 4 HC355
machine
Hydraulic rail
2 Station 3 TR75
tensioner
3 Rail impactor Sset 8
Hydraulic
4 Station 12
lifting machine
5 Driller Station 2
6 Track detector Station 1
41
 7 Subway Car 1
8 Utility vehicle Car 1
9 Flatbed truck Car 2
10 Theodolite Station 1
11 Spirit level Station 1
12 Roller A 350 φ20mm
13 Square ruler A 1
Rail
14 Piece 4
thermometer
15 Hand hammer A 20 8磅
16 Wrench A 15
17 Crowbar A 30
施工机具表
序号 名称 单位 数量 型号
1 锯轨机 台 4 HC355
液压钢轨拉伸
2 台 3 TR75
器
3 撞轨器 套 8
4 液压起拔道机 台 12
5 钻孔机 台 2
6 轨道检测仪 台 1
7 轨道车 辆 1
8 工具车 辆 1
9 平板车 辆 2
10 经纬仪 台 1
11 水平仪 台 1
12 滚筒 个 350 φ20mm
13 方尺 把 1
14 轨温表 块 4
15 手锤 把 20 8磅
16 扳手 把 15
17 撬棍 根 30

IV. Detailed rules for the operation

四、作业细则
4.1 Stress release and locking operation
4.1 应力放散及锁定作业

42
 The two long rails in the unit rail section shall be simultaneously stressed and
locked.
单元轨节中的两根长轨应同时进行应力放散及锁定作业。
The stress relief and locking operations of the unit rail joint can be divided into
two cases:
单元轨节的应力放散及锁定作业可分为两种情况:
1.When the actual measured rail temperature is within the range of the planned
locked rail temperature (which is a range), you can only use the roller to cooperate
with the rail impactor to release the stress.
1.当实测轨温处于计划锁定轨温(是一个范围)范围内时，可以仅用滚筒配合
撞轨器进行应力放散。
2. When the actual measured rail temperature is lower than the planned locked
rail temperature (which is a range), you need to use the rail puller, rail impactor and
other equipment to cooperate with the operation, and uniformly stretch the unit rail to
reach the actual locked rail temperature. The length makes it possible to lock the rail
temperature in one step.
2、当实测轨温低于计划锁定轨温(是一个范围)范围时，则需要利用拉轨器、
撞轨器等设备配合作业，通过均匀拉伸单元轨使其达到实际锁定轨温时应有的长
度，从而使锁定轨温一步到位。
4.1.1 Drum release method
4.1.1 滚筒放散法
1. Calculate the release amount: The release amount is calculated according to
the following formula:
ΔL = αx L x (TSS-TP)
In the style:
ΔL¬——Release amount (mm)
α——linear expansion coefficient of rail steel, α = 11.8x10-6 / ℃
L——Unit rail section length (mm)
TSS——Actual locked rail temperature (℃)
TP——average rail temperature during track laying (one track temperature value
every 300m during track laying, taking one section of each track temperature).
When the actual locked rail temperature is lower than the average track
temperature, ΔL is negative, that is, the unit rail section is shorter after release. At this
time, a corresponding short track needs to be prepared and placed on the unlocked end
of the unit rail section. For temporary connection.
When the actual locked rail temperature is higher than the average track
temperature, the rails need to be sawn after release.
1、计算放散量: 放散量按下列公式计算:
ΔL=α x L x (TSS-TP)

43
 式中:
ΔL ——放散量(mm)
α——钢轨钢的线膨胀系数，α=11.8x10-6/℃
L——单元轨节长度(mm)
TSS——实际锁定轨温(℃ )
TP——铺轨时的平均轨温(铺轨时每 300m 一个轨温值，取各轨温的平均值)。
当实际锁定轨温低于铺轨平均轨温时，ΔL 为负值，即放散后单元轨节要短
一截，此时需要准备一相应的短轨，放在单元轨节的未锁定端，作临时连接用。
当实际锁定轨温高于铺轨平均轨温时，放散后则需锯轨。
2. Set a stress release displacement observation point every 150m around the
track pitch and the middle of the unit, and observe the movement of the rail relative to
the sleeper during the stress release process. The observation point can be set on the
upper surface of the rail bottom or on the rail waist.
2、在单元轨节两端及中间每隔 150m 左右设一个应力放散位移观测点，观
测钢轨在应力放散过程中相对于轨枕的移动量。观测点可设在轨底上表面或轨腰
上。
3. Release all fasteners within 25-75m of the end of the rail section of the unit
and the seamless line welded to it.
3、解除本单元轨节和与之焊连的无缝线路末端 25-75m 范围内的所有扣件
约束。
4. Lift the steel rail with a track lifter, and put a roller at the bottom of the rail
every 15 ~ 20 sleepers, causing the bottom of the rail to be 20mm higher than the
rubber pad, which is in a freely retractable state. When the actual locked rail
temperature is higher than the average rail temperature of the laying rail, within a
range of 30m at the end of the unit rail section, a gradually increasing roller is placed
every 5m to make the bottom of the end rail 180mm higher than the rubber pad.
4、用起道机抬起钢轨，每隔 15～20 根轨枕在轨底放入一个滚筒，使得轨底
高出橡胶垫 20mm，处于自由伸缩状态。当实际锁定轨温高于铺轨平均轨温时在
单元轨节的末端 30m 范围内，每隔 5m 放置一个逐渐垫高的滚筒，使末端轨底
高出橡胶垫 180mm。
5. Every 350 ~ 400m on a straight line, and a curve hit point should be set every
300m when the curve and the uphill direction are scattered.
5、直线上每隔 350～400m、曲线及向上坡方向放散时每隔 300m 设一个撞
轨点。

44
 6. Hit the rail with a rail impactor and observe the change in displacement at
each point. When the rail displacement rebounds and the displacement of each point
changes, it is considered that the rail has reached a freely retractable state, and the rail
collision is stopped at this time; otherwise, the drum should be checked for tilt, tilt,
rail fall, and insufficient impact.
6、用撞轨器撞击钢轨，同时观测各点的位移量变化情况。当钢轨位移发生
反弹且各点位移变化均匀时，则视为钢轨达到自由伸缩状态，此时停止撞轨；否
则，应检查滚筒有无倾斜、脱落，钢轨有无落槽及撞击力不够等现象。
7. After confirming that the stress relief of the long rails of the unit is completed,
if you need to saw the rails, follow the rail sawing procedure to saw the rails, and it is
required that the rail end is not perpendicular to not more than 0.8mm.
7、确认单元长轨应力放散完毕后，若需锯轨则按锯轨操作程序锯轨，要求
轨端不垂直度不大于 0.8mm。
8. Remove the roller to make the long rail fall smoothly into the bearing groove.
At the same time, check the rubber pads and correct the misaligned ones.
8、撤掉滚筒，使长轨平稳地落入承轨槽内，同时检查橡胶垫，有错位者纠
正。
9. Distribute the workers uniformly within the range of the long rail for stress
release, measure and record the rail temperature when the fastener is started, and
perform the fastener operation at the same time, one every two, the end of the
seamless line 25 All the fasteners within the range of ~ 75m are tightened, and the
non-porous rail joints are tightened (the rail gap is still cushioned with a thin rail head
of about 20mm to keep the rail gap at 25 ± 2mm). locking. Record that the rail
temperature at this time is the rail temperature at the end, and continue to tightly
complete all the remaining fasteners.
9、将作业人员均布在进行应力放散长轨范围内，测量并记录开始紧扣件时
的轨温，同时进行紧扣件作业，每隔两根紧一根，无缝线路尾端 25～75m 范围
内的扣件全部紧完，并上紧无孔钢轨接头( 轨缝处仍用 20mm 左右的薄轨头片
衬垫，以保持轨缝为 25 ±2mm)，此时视为长轨已锁定。记录此时轨温为结束时
轨温，同时继续紧完其余全部扣件。
10. Calculate the average rail temperature at the beginning and end of the locking
operation as the actual locked rail temperature, and record it. At the same time, a clear
and standardized mark is made at the position corresponding to the displacement
observation pile and the rail waist (or the upper surface of the rail bottom).
10、计算锁定作业开始与结束时的平均轨温为实际锁定轨温，记录在案。同
时在位移观测桩和轨腰(或轨底上表面)相对应处，作出清晰的、规范的记号。
4.1.2 Comprehensive release method
45
 4.1.2 综合放散法
1. Calculate the stretch amount: The stretch amount of the long rail is calculated
according to the following formula:
ΔL = αx L x (TSS-Td)
In the style:
ΔL¬——Stretching amount (mm)
α——linear expansion coefficient of rail steel, α = 11.8x10-6 / ℃
L——Unit rail section length (mm)
TSS——Actual locked rail temperature (℃)
Td-Actual rail temperature at the time of Td-lock operation (C)
1、计算拉伸量: 长轨拉伸量按以下公式计算:
ΔL=α x L x (TSS-Td)
式中:
ΔL ——拉伸量(mm)
α——钢轨钢的线膨胀系数，α=11.8x10-6/℃
L——单元轨节长度(mm)
TSS——实际锁定轨温(℃ )
Td 一锁定作业当时实际轨温(C )
2. Make the rails in a freely retractable state. The operation procedure is the same
as that of 2 to 6 in 4.1.1 of the roller release method. The end of the fourth unit rail
section does not need to be raised 180mm, and the bottom of the rail is 20mm higher
than the rubber pad.
2、使钢轨处于自由伸缩状态,其作业程序同滚筒放散法中 4.1.1 中 2～6 条，
其中第 4 条单元轨节的末端无需抬高 180mm，轨底高出橡胶垫 20mm 即可。
3. Make zero mark of tensile displacement at each observation point.
3、在各观测点上做出拉伸位移的零点标记。
4. Measure the distance between the tail end of the long rail and the rail end of
the next unit rail. After replacing the width of the rail gap that should be left, compare
with the calculated stretching amount to finally determine the amount of sawn rail,
and follow the operation of the sawed rail. The program saws the rail, the rail end is
not perpendicular to less than 0.8mm.
Lj = ΔL-Lx + Lf
In the formula:
Lj-saw amount
ΔL-Calculated stretch amount
Lx-the distance between the end of the long rail and the end of the next unit rail
when the long rail is in a free state
Lf -a pair of rail gap

46
 4、测量长轨尾端与下一个单元轨节轨端之间的距离，扣除应留的轨缝宽度
后，与计算的拉伸量对比，以最终确定锯轨量，并按锯轨的操作程序锯轨，轨端
不垂直度小于 0.8mm。
Lj=ΔL-Lx+Lf
式中：
Lj 一锯轨量
ΔL 一计算拉伸量
Lx 长轨处于自由状态时，长轨尾端与下一个单元轨节轨端之距离
——

Lf 一预留轨缝量

5. Install the rail puller, use the rail puller and the rail impactor to pull the steel
rail, and observe the change of the tensile displacement at each observation point.
After the stretch amount reaches a predetermined length, each observation point is
notified to make a mark. At this time, the rail impactor is still working. When the
observation points show a rebound amount at the working mark (the stress has been
uniformly distributed), stop the rail impact and keep the rail puller under pressure. Do
not drop the rail puller until the locking operation is completed. This causes the end of
the rail to shift.
5、安装拉轨器，利用拉轨器和撞轨器共同作用，拉伸钢轨，同时观测各观
测点拉伸位移的变化情况。拉伸量达到预定长度后，通知各观测点做出记号。此
时撞轨器仍然继续作业，当各观测点在所做记号处出现反弹量(应力放散已均匀),
停止撞轨，拉轨器保压，在锁定作业完成之前不得因拉轨器的失压而使轨端出现
位移。
6. Remove the rail impactor and roller to make the long rail fall smoothly into
the bearing rail. At the same time, check the rubber pads and correct the
misalignment.
6、撤除撞轨器及滚筒，使长轨平稳地落入承轨槽内，同时检查橡胶垫，有
错位者纠正。
7. Quickly distribute the workers to the length range of the stress-relieving long
rail, and perform the fastening fasteners at the same time. Fasten the string every two
other fasteners, and the fastener parts within the range of 25 ~ 75m at the end of the
seamless line. After all tightening, and tightening the non-porous steel rail joint (the
rail gap is still cushioned with a thin rail head of about 20mm to keep the rail gap at
25 ± 2mm). At this time, the long rail is considered to be locked. Continue to finish all
the remaining fasteners.

47
 7、将作业人员迅速均布到进行应力放散长轨的全长范围内，同时进行紧固
扣件作业，每隔两根紧固一根，无缝线路尾端 25～75m 范围内的扣件全部紧完，
并上紧无孔钢轨接头(轨缝处仍用 20mm 左右的薄轨头片衬垫，以保持轨缝为
25±2mm),此时视为长轨已经锁定。继续紧完其余全部扣件。
8. Remove the stretcher, check the actual stretched length of the long rail, and
convert the corresponding actual locked rail temperature value. If the value is within
the planned locked rail temperature range, it is confirmed as the actual locked rail
temperature and entered in the table. Rework the locked job.
8、撤除拉伸器，复核长轨实际拉伸长度，换算出对应的实际锁定轨温值，
该值若在计划锁定轨温范围内，则确认为实际锁定轨温，填入表内。否则锁定工
作重新返工。
9. During the operation, the "Record of stress release and lock operation of unit
rail joints" should be filled in time.V. QC
9、作业过程中应及时填写“单元轨节应力放散及锁定作业记录”表。
V．QC
五、质量控制
5.1 Stress release, line lock
5.1 应力放散、线路锁定
5.1.1 When stress is released, a displacement observation point shall be set every
100-150m. Pay close attention to the displacement of the rail during the release and
the rebound of the rail after the release to ensure uniform stress release.
5.1.1 应力放散时，应每隔 100～150m 设一个位移观测点，密切注视放散时
钢轨的位移量及放散终了钢轨的反弹确保应力放散均匀。
5.1.2 When the line is locked, the actual locked rail temperature must be strictly
controlled within the planned locked rail temperature. The difference between the
locked rail temperature of two steel rails is ≤3 ° C, and the difference between the
locked rail temperatures of two adjacent unit rail sections is ≤5 ° C. The difference
between the maximum and minimum locked rail temperatures of a long rail with the
same design locked rail temperature is ≤10 ° C. After the line is locked, the zero point
should be marked on the rail immediately. The zero point is marked on the outside of
the rail head in the form of a positive triangle on a white background, and the
corresponding displacement observation pile number is marked on the rail waist.
5.1.2 线路锁定时实际锁定轨温必须严格控制在计划锁定轨温之内。两股钢
轨的锁定轨温差≤3℃,相邻两段单元轨节锁定轨温之差≤5℃，同一设计锁定轨
温的长轨条最高与最低锁定轨温之差≤10℃。线路锁定后，应立即在钢轨上标记

48
零点位置。零点标记在轨头外侧，形式为白底正红三角，轨腰处标记相对应的位
移观测桩编号。
5.1.3 After the line is locked, regularly observe the rail displacement and make
records. The relative displacement within each 200m of the displacement monitoring
is ≤10mm. The displacement at any displacement observation pile must not exceed
20mm.
5.1.3 线路锁定后，定期观测钢轨位移情况并作好记录，位移量监控每 200m
范围内相对位移量≤10mm，任何一个位移观测桩处位移量不得超过 20mm。
5.2 Displacement observation pile
5.2 位移观测桩
5.2.1 The style, specifications and materials of the displacement observation pile
shall meet the design requirements.
5.2.1 位移观测桩的式样、规格和材料应符合设计要求。
5.2.2 The displacement observation pile shall be set according to the logarithm
and position required by the design.
5.2.2 位移观测桩应按设计要求的对数和位置设置。
5.2.3 The displacement observation piles must be buried firmly and meet the
design requirements. The allowable deviation of the remaining height of the
displacement observation piles buried on the road shoulder is ± 3mm. The height of
the displacement observation piles installed on the catenary pole should be the same,
50 ～ 100mm above the rail surface. , The number is correct, the font is straight,
clear, and the pull line of the pull port is perpendicular to the center of the line.
5.2.3 位移观测桩必须埋设牢固，符合设计要求，路肩上埋设的位移观测桩
的剩余高度允许偏差为±3mm,在接触网杆上设置的位移观测桩高度应一致，高出
轨面 50～100mm，编号正确，字体端正、清晰、拉线口的拉线与线路中心垂直。
VI. Locked construction process
六、锁定施工工艺流程
6.1 Preparations before locking welding
6.1 锁定焊接前准备工作
(1) Assembly and debugging of welding equipment, rail form experiments
Assemble the equipment according to the assembly procedure and carry out
comprehensive commissioning. After confirming that all the equipment is normal, the
belt rails are welded in accordance with the specified inspection requirements for
formal inspection. After confirming that the welding parameters are qualified,
construction can begin.
（1） 焊接设备组装调试、钢轨形式实验

49
 按照组装程序进行设备组装，并进行全面调试。确认设备一切正常后将带焊
轨按照规定的检验要求焊接进行形式检验，确定焊接参数合格后可开始进行施工。
(2) Descaling and grinding of rail joints
Use a hand-held grinder to grind the rail joint end face and the 700mm range
between the rails on both sides and the conductive part of the welding machine. After
grinding, the surface of the rails should have a metallic luster, no rust, and the wear of
the base metal should not exceed 0.2mm. If the strip welding time after grinding
exceeds 24 hours or there is oil stain, it must be reground.
（2）钢轨接头除锈、打磨
在钢轨接头端面及两侧钢轨与焊机导电部位间 700mm 范围内采用手提式砂
轮机打磨，打磨后钢轨表面应有金属光泽，不得有锈蚀，对母材磨耗不得超过
0.2mm。若打磨后的带焊时间超过 24 小时或有油污，则必须重新打磨。
(3) Equipment inspection before rail welding
Before welding, check whether the main machine, cooling system, hydraulic
system, and electrical control system are normal according to the instructions of the
welding machine; check whether the power voltage, water temperature, water level,
oil temperature, and welding spatter on the knob knife are removed.
（3） 钢轨焊接前设备检查
焊接前应按照焊机使用说明检查主机、冷却系统、液压系统、电气控制系统
是否正常；检查动力电压、水温、水位、有油温、推瘤刀上的焊接飞溅物是否清
除干净。
6.2 Lock welding methods and important precautions and some common
problems encountered during construction
6.2 锁定焊接的方法及重要注意事项以及施工中遇到的一些常见问题
(1) Normally 1.5 kilometers is a locking point. Pay attention to whether the unit
roller is in place and whether the fasteners have completely disengaged from the
sleepers, especially when there is a large downhill curve with a large radius. The
density of the drum. The construction team used the stretcher and the rail impactor to
hit the rail to within 1 cm of the static end and the moving end rail, which has ensured
the normal operation of the lock welding.
（1）正常情况下一般 1.5 公里为一个锁定点，要注意单元滚筒有没有放到
位，扣件有没有完全脱离轨枕，特别是遇到有大下坡曲线半径较大的时候，要试
机增加滚筒的密度，施工队利用拉伸器和撞轨器将钢轨撞至静端于动端钢轨 1cm
以内，已保证锁定焊接的正常进行。
(2) Bend welding, especially when dealing with wounds and inserting short rails,
wire construction is extremely common. The moving end rail fastener is spread to 100
meters, and the opening position is to be bent at 40 to 50 meters. The amount of rails
50
for turning welding is extremely important. The current 150 welding machine
generally burns about 3.5cm after welding. Due to the weather, there will be a certain
amount according to the thermal expansion and contraction of the rail before and after
the saw. This factor must be taken into account when rails are cut. When sawing is
less, it is possible that the rails cannot enter the groove during the plucking process.
Otherwise, more welding ends are not enough, and these factors will increase the
probability of injury. The most important point of turning welding is the manual
turning at the end of welding. Generally, the turning is performed at the end of
acceleration one and acceleration two. The speed of the turning has a great influence
on the quality of welding. Causes a large disconnection in the acceleration phase, the
greater the acceleration is not faster, the larger the gray spot area, which makes the
flash stability worse, and is most vulnerable to injury.
（2）拨弯焊接，尤其是处理伤头，插入短轨，既有线施工极为常见。动端
钢轨扣件撒至 100 米处，开弯位置在 40 至 50 米处开弯。对于拨弯焊接据轨量极
为重要，现 150 焊机一般情况下焊接过后烧化量为 3.5cm 左右，由于天气的原因
据锯轨前跟锯轨后钢轨热胀冷缩会有一定的量，锯轨的时候就要把这一因数考虑
在其中，锯少了在拨的过程中及有可能钢轨不能入槽，反之锯多了焊接最后顶端
量不够，这些因素都会加大出伤的机率。拨弯焊接最重要的一点就是在焊接最后
的人力拨弯，一般在加速一结束加速二开始的时候进行拨弯，拨弯的快慢与焊接
的质量有很大的影响，拨弯过程过早会造成加速阶段大断路，加速未速度越大，
灰斑面积越大，使闪光稳定性变差，最易出伤。

51